Bobbin

ABSTRACT

An electrical motor stator bobbin integrally formed of electrical insulating material having relatively enlarged end flanges and intervening sleeve or core for receiving thereabout the electrical winding. Said bobbin is provided with tubular members extending between said flanges and opening at its ends therethrough for receiving therein the ends of the winding and the joined portions of the coil leads. The flanges are provided with an arrangement of openings so that the leads may extend outwardly from the same flange or from opposite flanges.

United States Patent 1191 Russell Nov. 13, 1973 BOBBIN 456,739 7/1968Switzerland 336/192 l l9 1 Invent my Russell, Washington, "3333222 Z13232221mm 332/193 [73] Assignee: Von Welse Gear Co., St. Louis, Mo.

{22] Filed: May 16, 1972 Primary Examiner-Thomas J. Kozma [211 pp No253,795 Attorney- -Ralph W. Kalish [52] US. Cl 336/192, 310/194, 336/198[51] Int. Cl. H0lf 27/28 [57] ABSTRACT [58] Field of Search 336/192,208, 198; An electrical motor stator bobbin integrally formed of 310/194electrical insulating material having relatively enlarged 2 end flangesand intervening sleeve or core for receiv- [56] References Cited ingthe'reabout the electrical winding. Said bobbin is UNITED STATES PATENTSprovided with tubular members extending between 3,371,302 2/1968 Mas336/192 X said flanges and opening at its ends therethrough for1,647,372 11/1927 Pressley 2 receiving therein the ends of the windingand the 3,189,772 1965 winglef ct e e 310/194 X joined portions of thecoil leads. The flanges are prollarmlf etalvided with an arrangement ofopenings so that the amras 2,858,514 10/1958 Henderson et al 336/192 xleads may extend outwardly from the Same flange FOREIGN PATENTS ORAPPLICATIONS from opposite flanges.

Denmark 336/208 5 Claims, 8 Drawing Figures 9 Q a r y X l BACKGRQUND ANDSUMMARY OF THE INVENTION This invention relates in general to electricalmotors I and, more particularly, to a stator. bobbin therefor.

the inner end portion of the coil to the: bobbin core; in wrapping thejoined ends of the wire andv the exposed.

cable leads; and in enclosing the coil to prevent undesired displacementof the leads. Such. relative liberal usage of tape has been a source ofmarked expense and, obviously, the application of such tape has requirednecessary, costly labor.

Therefore, it is an object of the present invention to provide a bobbinof the character stated whichembodies means for receiving and retainingthe coil-ends without resort to insulating tape.

It is another object of the present invention to provide a bobbin of thecharacter stated which promotes low-cost, high-volume coil windingoperations.

It is a further object of the present invention to provide a bobbin ofthe type stated which maintains the coil leads against displacementduring usage without resort to extraneous means; and which is adapted topermit of facile inspection of the joint between. the winding end andthe coil leads.

It. is another object of the present invention to provide a bobbin ofthe type stated. which may be most cheaply manufactured and which isreliable and durable in usage.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an elevational view of amotor stator containing a bobbin constructed in accordance with andembodying the present invention.

FIG. 2 is a horizontal transverse sectional view take on the line 2-2 ofFIG. 1. I

' FIG. 3 is'a vertical transverse sectional view taken on the line 3--3of FIG. 1. I

FIG. 4is a vertical transverse sectional view taken on the line 4-4 ofFIG. 1.

FIG. 5 is an end view of another form of bobbin constructed inaccordance with and embodying the present invention, illustrating. samein operative condition with a winding thereabout.

FIG. 6 is a vertical transverse: sectional view taken on the line 6-6 ofFIG. 5. I

FIG. 7 is a vertical. transverse sectional view taken on the line 7-7 ofFIG. 5. a

FIG. 8 is a horizontal transverse sectional view taken on the line 8-8of FIG. 5.

DESCRIPTION OF THE PRACTICAL EMBODIMENTS but is set forth forillustration purposes only.

Bobbin A is fabricated of suitable electrical insulating material, suchas, nylon or the like, and incorporates a pair of planar parallel,projecting end flanges 5,6 formed at the end of an intervening core 7,which latter comprises upper andlower walls 8,9 and side walls 10,11;said core opening at its ends through flanges 5,6 thereby defining areceptacle for the intervening portion of stator l. The walls of core 7are located spacedly inwardly from the proximate edge of the relatedflanges 5,6 for defining a volume 12 to receive winding 4 which, forexample, is comprised of copper wire.

Formed in the outer face of wall 9, and being coextensive therewith, isa pair of axially parallel, spacedapart tubular members 13,1'4which openat their opposite ends through flanges 5,6 for defining passageways15,16, respectively. Said tubular members being thus integral withbobbin A are formed of the same electrical insulating material. As bestseen in FIGS. 1 and 4, winding 4 will extend about the exterior of saidmembers 13,14.

Also provided in flange 5 substantially intermediate the end opening oftubular members 13,14, but spaced apart outwardly thereof, is arelatively enlarged aperture 17. The inner end 18 of winding 4 is ledoutwardly through aperture 17 and thence inwardly of passage 16 oftubular member 14. The outer end 19 of winding 4 is led outwardly fromvolume 12 through aperture 17 and then is turned inwardly for projectioninto passage 15 of tubular member 13.

As may best be seen in FIG. 2, within passages 15,16, winding ends 18,19are each fixed, as by brazing, at 20,21, respectively, to the exposedend 22,23 of a customary coil lead 24,25, respectively. The said coilleads 24,25 thus project outwardly of the ends of passages 15,16 inflange 6 for the usual circuit-establishing purposes. As shown in FIGS.1 to 4, said leads may, if desired, be returned through guide openings,as at 26,27, formed in flange 6 (see FIG. 3).

It will thus be seen that the union of the ends 18,19 of winding 4 andthe respective coil leads is maintained within passageways 15,16, thewalls of which provide complete insulation so that the usual wrapping ofelectrical tape about the developed joint is obviated. Accordingly,tubularmembers 13,14 constitute protective chambers, the use of whichboth facilitate winding of bobbin A, as well as any inspection or repairrequired of the union, while simultaneously obviating the heretoforeaccepted utilization of relatively substantial quantities of insulatingtape. Additionally, the inner diameters of passageways 15,16 aresubstantially the same as the outside diameter of the insulated portionsof leads 24,25, as indicated at 28,29, so that a reasonably snug fit isdeveloped therebetween; allowing of rel ative movement of the leadstherein under limited pressure for assembly purposes, but maintainingsaid leads against undesired displacement during usage. The relativemaintenance of leads 24,25 by tubular members 13,14 prevent thedevelopment of any undue strain upon the coil leads. Prior to thepresent invention tape was used to secure the inner end of the coil inappropriate position; as well as to enwrap the joined ends of the coiland the leads; and to enclose the coil for prevent ing undesireddisplacement of the leads.

From the foregoing the required assembly is immediately apparent asleads 24,25 may be inserted through passageways 15, 16 to present theirexposed portions 22,23 for brazing with the related ends of winding 4.Subsequent thereto, leads 24,25 are withdrawn sufficiently throughpassageways 16,15 to locate the developed union, as at 20,21,substantially centrally of the aforesaid passageways.

Referring now to FIGS. 5-8, inclusive, A designates a bobbin which is ofthe same general construction as bobbin A above described so that likeparts will bear the same reference numerals. Formed in each end flange5,6 of bobbin A equidistant from the proximate end openings of passages15,16, but being located outwardly toward the adjacent edge of therelated flange, is an aperture 30,31, respectively, which is continuousin its core-adjacent portion with a narrow, slot-like opening 32,33which progresses between tubular members 13,14 for terminating at theadjacent core wall 9. The inner end 18 of winding 4 is directed throughaperture 31 and thence through opening 33 for direction into passage 16of tubular member 14; for joinder, in the manner above described, to theexposed end of coil lead 24. The outer end 19 of winding 4 is directedoutwardly of flange 6 through aperture 30 and is then directedreturningly inwardly through passage 15 of tubular member 13 forengagement to the exposed end of coil lead 26. It will thus be seen thatthe ends 18,19 of winding 4 are directed through the respectivepassageways 16,15 in opposite directionsso that coil lead 24 will belocated outwardly of flange 6, while coil lead 25 will be presentedbeyond flange 5. Each of said leads 24,25 may, if desired, be redirectedthrough the respective flanges by extension through guide openings 34,35within flanges 6,5, respectively.

As shown hereinabove, bobbin A is designed to provide for coil leads24,25 extending from the same end thereof, while bobbin A is constructedto conduce to the extension of said leads from opposite ends thereof inorder that the same are presented for particular applications. Thus, theincorporation of apertures 30,31 and slot-like openings 32,33 in flanges5,6, respectively, promote the desired cable direction.

In view of the foregoing, it is to be seen that the present inventioneliminates the need for insulating tape in the formation of statorwindings as has been the practice to the present time. The obviation ofthe need for tape brings about a most substantial relative costreduction, both from the standpoint of material, as well as labor; whilesimultaneously rendering any repair or inspection easily achievable.

Having described my invention what I claim and desire to obtain byLetters Patent is:

1. In combination with a predetermined length of uninsulated conductivewire having a normally inner end and an outer end, and a pair ofinsulated leads having exposed ends, means joining the exposed ends ofsaid insulated leads to said conductive wire inner and outer ends, theimprovement comprising an electrical motor stator bobbin beingfabricated of dielectric material and having parallel end flanges, meansdefining a core between, and connected to, said end flanges for windingdisposition of said conductive wire thereabout, a pair of enclosedtubular passageways extending between said end flanges and opening attheir ends therethrough, the cross section of said passageways beinggreater than the diameter of the conductive wire and substantially thesame as the cross section of the insulated leads for tending to inhibitdisplacement of said leads therein, the joined inner and outer ends ofsaid conductive wire and said insulated lead ends being disposed withinsaid passageways thereby protecting the joint developed therebetween.

2. In combination with a predetermined length of uninsulated conductivewire having a normally inner end and an outer end, and a pair ofinsulated leads having exposed ends, means joining the exposed ends ofsaid insulated leads to said conductive wire inner and outer ends, theimprovement as defined in claim 1 and further characterized by one endflange of said bobbin having an opening located between the adjacentends of said tubular passageways and outwardly thereof, said outer andinner, ends of said wire being directed from the winding thereof aboutsaid core outwardly through said opening and thence directed returninglytoward the proximate flange for extension into the respective tubularpassageway.

3. In combination with a predetermined length of uninsulated conductivewire having a normally inner end and and outer end, and a pair ofinsulated leads having exposed ends, means joining the exposed ends ofsaid insulated leads to said conductive wire inner and outer ends, theimprovement as defined in claim 2 and further characterized by saidother end flange having a pair of guide openings for projectiontherethrough of portions of said insulated leads extending outwardlyfrom the respective tubular passageways.

4. In combination with a predetermined length of uninsulated conductivewire having a normally inner end and an outer end, and a pair ofinsulated leads having exposed ends, means joining the exposed ends ofsaid insulated leads to said conductive wire inner and outer ends, theimprovement as defined in claim 1 and further characterized by anopening formed in each end flange between but slightly outwardly of theproximate ends of the tubular passageways, there being an elongatednarrow aperture communicating with one of said openings and extendingtherefrom in a direction of the core and terminating between theproximate ends of the related passageways, the inner end of saidconductive wire passing from said winding through said elongate narrowaperture and thence returningly into the related passageway, the outerend of said conductive wire extending outwardly through one of saidopenings and thence being directed returningly into the relatedpassageway.

5. In combination with a predetermined length of uninsulated conductivewire having a normally inner end and an outer end, and a pair ofinsulated leads having exposed ends, means joining the exposed ends ofsaid insulated leads to said conductive wire inner and outer ends, theimprovement as defined in claim 1 and further characterized by saidtubular passageways being provided outwardly of said core, saidpassageways being mutually axially parallel and being axially normal tothe plane of said end flanges.

1. In combination with a predetermined length of uninsulated conductivewire having a normally inner end and an outer end, and a pair ofinsulated leads having exposed ends, means joining the exposed ends ofsaid insulated leads to said conductive wire inner and outer ends, theimprovement comprising an electrical motor stator bobbin beingfabricated of dielectric material and having parallel end flanges, meansdefining a core between, and connected to, said end flanges for windingdisposition of said conductive wire thereabout, a pair of enclosedtubular passageways extending between said end flanges and opening attheir ends therethrough, the cross section of said passageways beinggreater than the diameter of the conductive wire and substantially thesame as the cross section of the insulated leads for tending to inhibitdisplacement of said leads therein, the joined inner and outer ends ofsaid conductive wire and said insulated lead ends being disposed withinsaid passageways thereby protecting the joint developed therebetween. 2.In combination with a predetermined length of uninsulated conductivewire having a normally inner end and an outer end, and a pair ofinsulated leads having exposed ends, means joining the exposed ends ofsaid insulated leads to said conductive wire inner and outer ends, theimprovement as defined in claim 1 and further characterized by one endflange of said bobbin having an opening located between the adjacentends of said tubular passageways and outwardly thereof, said outer andinner ends of said wire being directed from the winding thereof aboutsaid core outwardly through said opening and thence directed returniNglytoward the proximate flange for extension into the respective tubularpassageway.
 3. In combination with a predetermined length of uninsulatedconductive wire having a normally inner end and and outer end, and apair of insulated leads having exposed ends, means joining the exposedends of said insulated leads to said conductive wire inner and outerends, the improvement as defined in claim 2 and further characterized bysaid other end flange having a pair of guide openings for projectiontherethrough of portions of said insulated leads extending outwardlyfrom the respective tubular passageways.
 4. In combination with apredetermined length of uninsulated conductive wire having a normallyinner end and an outer end, and a pair of insulated leads having exposedends, means joining the exposed ends of said insulated leads to saidconductive wire inner and outer ends, the improvement as defined inclaim 1 and further characterized by an opening formed in each endflange between but slightly outwardly of the proximate ends of thetubular passageways, there being an elongated narrow aperturecommunicating with one of said openings and extending therefrom in adirection of the core and terminating between the proximate ends of therelated passageways, the inner end of said conductive wire passing fromsaid winding through said elongate narrow aperture and thencereturningly into the related passageway, the outer end of saidconductive wire extending outwardly through one of said openings andthence being directed returningly into the related passageway.
 5. Incombination with a predetermined length of uninsulated conductive wirehaving a normally inner end and an outer end, and a pair of insulatedleads having exposed ends, means joining the exposed ends of saidinsulated leads to said conductive wire inner and outer ends, theimprovement as defined in claim 1 and further characterized by saidtubular passageways being provided outwardly of said core, saidpassageways being mutually axially parallel and being axially normal tothe plane of said end flanges.